Yamaha YFM125S Bedienungsanleitung

YFM125S

3FA-AE2

SUPPLEMENTARY

SERVICE MANUAL

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the

YFM125S. For complete service information procedures it is necessary to use this Supplementary

Service Manual together with the following manual.

YFA1W SERVICE MANUAL: 3FA-ME1

YFA1(P) 2002 SUPPLEMENTARY SERVICE MANUAL: 3FA-AE1

YFM125S

SUPPLEMENTARY

SERVICE MANUAL

First edition, January 2004

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

EBS00002

NOTICE

This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers

and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one

manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on

Yamaha machine has a basic understanding of the mechanical ideas and the procedures of

machine repair. Repairs attempted by anyone without this knowledge are likely to render the

machine unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and sig-

nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers

and will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

EBS00003

IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following notations.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death

to the machine operator, a bystander or a person checking or repairing the

machine.

A CAUTION indicates special precautions that must be taken to avoid dam-

age to the machine.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

EBS00004

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See “symbols”)

1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.

2nd title 2: This title indicates the section of the chapter and only appears on the first page of each

section. It is located in the upper left corner of the page.

3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa-

nied by corresponding illustrations.

EXPLODED DIAGRAMS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section.

1. An easy-to-see exploded diagram 4is provided for removal and disassembly jobs.

2. Numbers 5are given in the order of the jobs in the exploded diagram. A number that is enclosed

by a circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks

6. The meanings of the symbol marks are given on the next page.

4. A job instruction chart 7accompanies the exploded diagram, providing the order of jobs, names

of parts, notes in jobs, etc.

5. For jobs requiring more information, the step-by-step format supplements 8are given in addition

to the exploded diagram and the job instruction chart.

EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols 1to 8are printed on the

top right of each page and indicate the subject

of each chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Engine

5Carburetion

6Chassis

7Electrical

8Troubleshooting

Illustrated symbols 9to Eare used to identify

the specifications appearing in the text.

9Filling fluid

0Lubricant

ASpecial tool

BTorque

CWear limit, clearance

DEngine speed

EΩ, V, A

Illustrated symbols Fto Lin the exploded

diagrams indicate the types of lubricants and

lubrication points.

FApply engine oil

GApply gear oil

HApply molybdenum disulfide oil

IApply wheel bearing grease

JApply lightweight lithium soap base grease

KApply molybdenum disulfide grease

LApply silicon grease

Illustrated symbols Mto Nin the exploded

diagrams indicate where to apply a locking

agent Mand when to install a new part N.

MApply the locking agent (LOCTITE®)

NReplace

FGH

GEN

INFO SPEC

CHK

ADJ ENG

CARB CHAS

–+

ELEC TRBL

SHTG

EGM

BLS MS

JKL

New

CONTENTS

SPECIFICATIONS ............................................................................................1

GENERAL SPECIFICATIONS ..................................................................1

MAINTENANCE SPECIFICATIONS .........................................................2

ENGINE ................................................................................................2

CHASSIS ..............................................................................................2

ELECTRICAL ........................................................................................3

CABLE ROUTING .....................................................................................4

PERIODIC CHECKS AND ADJUSTMENTS ..................................................17

SEAT, CARRIERS AND FENDERS ........................................................17

SEAT, FRONT CARRIER, FRONT BUMPER AND CENTER COVER ....17

FRONT GRILL ASSEMBLY AND FRONT FENDER ..........................19

REAR CARRIER AND REAR FENDER ..............................................20

ELECTRICAL ..........................................................................................22

ADJUSTING THE HEADLIGHT BEAMS ............................................22

REPLACING A HEADLIGHT BULB ....................................................22

ELECTRICAL .................................................................................................24

IGNITION SYSTEM .................................................................................24

CIRCUIT DIAGRAM ............................................................................24

CHARGING SYSTEM .............................................................................25

CIRCUIT DIAGRAM ............................................................................25

LIGHTING SYSTEM ................................................................................26

CIRCUIT DIAGRAM ............................................................................26

TROUBLESHOOTING ........................................................................27

SIGNAL SYSTEM ...................................................................................29

CIRCUIT DIAGRAM ............................................................................29

CHECKING THE SIGNALING SYSTEM .............................................30

YFM125S WIRING DIAGRAM

–1 –

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Model YFM125S

Model code number 1C51: (for Oceania)

1C53: (for CDN)

1C54: (for Europe)

Dimensions

Overall length 1,710 mm (67.3 in)

Overall width 990 mm (39.0 in)

Overall height 980 mm (38.6 in)

Seat height 705 mm (27.8 in)

Wheelbase 1,080 mm (42.5 in)

Minimum ground clearance 145 mm (5.7 in)

Basic weight

Wet (with oil and a full fuel tank) 152 kg (335 lb)

Dry (without oil and fuel) 144 kg (317 lb)

Maximum load (except vehicle) 100 kg (220 lb)

Fuel

Type Regular unleaded gasoline only (for CDN and

Europe)

Unleaded gasoline only (for Oceania)

Fuel tank capacity 7.6 L (1.67 Imp gal, 2.01 US gal)

Reserve amount 1.3 L (0.28 Imp gal, 0.34 US gal)

Spark plug

Type/manufacturer CR7HS/NGK

Spark plug gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in)

Electrical

Ignition system DC C.D.I.

Generator system A.C. magneto generator

Battery capacity 12V 12Ah

Battery type 12N12C-4A-2

Headlight type Bulb type

Headlight bulb type Krypton

Bulb wattage (quantity)

Headlight 12 V 30 W/30 W (2 pc.)

Tail/brake light 12 V 5 W/21 W (1 pc.)

Neutral indicator light 12 V 1.7 W (1 pc.)

Reverse indicator light 12 V 1.7 W (1 pc.)

GENERAL SPECIFICATIONS

–2 –

SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

CHASSIS

Tightening torques

Model YFM125S

Carburetor

I.D. mark 5VJ2 10

Main jet (M.J) # 77.5

Main air jet (M.A.J) ø1.3

Jet needle (J.N) 4HPY46-1

Needle jet (N.J) O-1M

Cutaway (C.A) 2.5

Pilot air jet (P.A.J) # 130

Pilot outlet (P.O) ø0.7

Pilot jet (P.J) # 12.5

Bypass 1 (B.P.1) 1.1

Pilot screw (P.S) 2 and 1/2 turns out (for Europe and Oceania)

Valve seat size (V.S) 1.8

Starter jet (G.S) # 45

Fuel level (F.L) 3.5 ~ 4.5 mm (0.14 ~ 0.18 in)

With special tool

Engine idling speed 1,650 ~ 1,750 r/min

Intake vacuum 26.7 kPa (200 mmHg, 7.88 inHg)

Part to be tightened Thread size Tightening torque Remarks

Nm m ·kg ft ·lb

Footrest board and footrest bracket M5 7 0.7 5.1

Footrest and footrest bracket M6 10 1.0 7.2

Front fender and frame M6 7 0.7 5.1

Front carrier and front grill M6 7 0.7 5.1

Fuel tank M6 10 1.0 7.2

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